Coated mulch sheet



Feb. 11, 1969 R. F.1.IPPoLDT ETAL 3,427,194

COATED MULCH SHEET Filed Nov. 27, 1964 TELCEL- 1 a INVENTORS Q/cHAQ/J F. L/'ppozr ,6 WAQQf-N VV, WOODS United States Patent O M 4 Claims ABSTRACT OF THE DISCLOSURE Mulch sheet comprising a fibrous biodegradable porous cell-ulosic sheet such as paper, coated on one surface with a composition comprising asphalt and a copolymer of ethylene-vinyl acetate or ethylene-ethyl acrylate.

This invention relates to mulching materials and seed mats for use in agriculture for selectively promoting the growth of certain plant types. More particularly, the present invention pertains to agricultural mulches and seed mats f the type comprising sheets of a (fibrous substrate which has been in some manner treated with a bituminous composition, and to the methods of manufacturing mulches and seed mats of this type.

It is now Well established that certain types of paper or fibrous mulches can afford marked benefit in enhancing the growth of certain plants while suppressing undesirable growth of different types, such as weeds and the like. Elongated strips of untreated paper were initially used as mulch materials and functioned well for short periods of time. However, the paper often rotted or disintegrated prior to the end of the growing season, and also had other defects or disadvantages which rendered its use of marginal value in many circumstances.

It was next proposed to coat or impregnate paper or fibrous strips with some type of fiexible, water-repellant, resinous or semiplastic material, such as tar or asphalt. This improved the water retention in the soil and the amount of heat absorption and insulation afforded by the mulch. One of the problems which was engendered by impregnating the paper of fibrous stock with asphalt or tar. However, was that of disposing of the mulch paper after the growing season when it was desirable to plow under the stubble or otherwise prepare the field for the next season. Although the untreated paper mulches had been sufiiciently biodegradable that they were easily disintegrated and consumed by soil organisms by the end of the harvest to avoid this problem, asphalt impregnation apparently reinforced the paper and made it sufficiently unpalatable to soil organisms that it remained substantially intact in the field beyond the period of its usefulness. Moreover, the tendency of the asphalt to block at high temperatures, and the inability to fiex upon rolling or bending over small radii made handling and storage of long strips of this type of mulch difficult.

More recently, two techniques of mulching have been proposed which are basic departures from the types of mulches which employ paper or fibrous stock, either alone, or treated with a suitable material for improving certain of the properties of the paper. In one of these, asphalt emulsions are sprayed on the soil directly over the 3,427,194 Patented Feb. 11, 1969 seed row. The main advantages of this type of mulching procedure are that it is relatively economical compared to other mulches, and that the asphaltic particles can be easily plowed under after each crop has matured without detriment to the soil.

In the other type of mulching procedure currently in widespread use, sheets of thin, black polyethylene film are used. The film is about 1.25 mils thick and is applied in strips about twenty inches wide over the seed row. Since the plastic is not attacked or consumed by soil organisms, it is necessary to gather -up the plastic sheets after use and burn them, and the total cost of the mulching operation is thereby substantially increased.

The present invention comprises a new type of mulch which possesses the desirable qualities attributable to the earlier asphalt-impregnated paper mulches, but which is not characterized by the disadvantages which previously characterized this type of mulch. Moreover, the mulches of this invention can be manufactured substantially more economically than polyethylene film mulches, and in certain embodiments, can be made slightly less expensively than the previously used asphaltor tar-coated paper mulches. Moreover, the mulches of the present invention are considerably more effective in promoting crop growth than the sprayed-on asphalt emulsions and last longer than such emulsions, which tend to disintegrate too early in the growing season to provide protection for slow growing crops.

In another aspect, the present invention comprises a novel seed mat containing in-situ seeds which are carried by a porous, fibrous substrate.

More specifically described, the present invention comprises a fibrous matrix or substrate of a porous, biodegradable material, such as cellulose, which has applied thereto a relatively thin layer or coating of a bitumincontaining material. In one embodiment, seeds are placed upon, or embedded in, the fibrous matrix before covering the matrix with the bitumin-containing material. The relationship of the coating of bitumin-containing material to the substrate is of some criticality, it being desirable to limit the thickness of the coating to less than 3.5 mils in the case of the mulch and less than about 6 mils in the case of the seed mats. It is also important to prevent penetration of the coating material into the pores or interstices of the substrate more than is necessary to assure good ad hesion of the coating to the fibrous stock. To the end of accomplishing the preferred relationship between the iibrous matrix and the bitumin-containing coating, a novel method of fabricating the mulches of the invention is proposed and broadly comprises establishing a thin, gravitating film of the molten bitumin-containing composition and passing the substrate through the film under conditions to lay down thereon a coating of the desired thickness and depth of penetration.

The major advantages which accrue from the described relationship of the coating material to the substrate are economy in materials savings and improved disposability of the mulch after it has served its purpose. The mulches made by the preferred method of fabrication appear to be more readily attacked by microorganisms in the soil which attack and substantially entirely consume the paper substrate over the course of most growing seasons. The bituminous coating, then lacking support, disintegrates easily and can be plowed under the soil with no difficulty.

Apparently, the shallow penetration of the coating material into the paper or cellulosic substrate permits better access by cellulose-consuming bacteria, so that the substrate can be more quickly destroyed.

Additionally, the described gravitating curtain method of applying the coating to the substrate results in a more uniform coating with fewer discontinuities, cracks or breakthroughs which weaken the mulch mechanically or permit moisture to escape from the earth.

The brous substrate can be substantially any porous, 'biodegradable material having mechanical properties similar to paper and can typically he either paper or cloth. The bitumin-containing coating composition can -be a pure asphaltic material, but is preferably a composition comprising asphalt and from about 1 percent by weight to about percent by weight of an asphalt extendible copolymer. The asphalt extendible copolymer imparts greater exibility and mechanical strength to the bitumin and also increases the moisture-retention properties of the mulch. It also assists in preventing blocking of the coating when the mulch is rolled up for storage and transport.

From the foregoing description of the invention, it will have -become apparent that it is a major object of the 'present invention to provide a novel agricultural mulch having improved mulching characteristics, and which may be relatively economically manufactured.

Another object of the invention is to provide an improved seed mat for growing plants from an artificial mulch-type environment.

An additional object of the present invention is to provide a novel and improved method for manufacturing mulches of the type having a fibrous, biodegradable substrate with a coating of a bituminous composition applied to such substrate.

A more specific object of the present invention is to prepare an agricultural mulch of the type having a paper matrix or substrate carrying a thin coating of a bitumincontaining composition, and which undergoes degradation or decomposition by soil organisms more rapidly than mulches of this general character which have been previously manufactured.

An additional object of the present invention is to provide a novel mulch material for use in enhancing plant growth which attains the advantages heretofore characteristic of asphaltic-type mulches, but which demonstrates improved physical properties including better blocking properties, improved flexibility, and better moisture-retention.

A further object of the present invention is to provide a method for manufacturing agricultural mulches of the type having ra paper or fibrous substrate coated or impregnated with asphaltic compositions, which method per- `mits the asphaltic or bitumin-contaiuing composition to be more uniformly applied to the substrate with less penetration of the substrate and ybetter control of the thickness of the asphaltic layer -being affected.

An additional object of the present invention is to provide an agricultural mulch which is at least comparable in performance with sheet polyethylene mulch, but which can be manufactured more economically, and which is more readily disposed of at the end of the growing season than sheet polyethylene-type mulches.

In addition to the foregoing described objects and advantages, additional objects and advantages will become apparent as the following detailed description of the invention is read in conjunction with the accompanying drawings which illustrate various aspects of the invention.

In the drawings:

FIGURE 1 is a transverse sectional View through a strip of the novel agricultural mulch of the present invention, showing the relationship of the substrate and the coating which is applied thereto.

FIGURE 2 is a perspective, partially schematic, illustration of an apparatus which can be used in practicing the novel method used for fabricating the agricultural mulches and seed mats of the invention.

FIGURE 3 is a transverse sectional view through a seed mat constructed in accordance with the teachings of the present invention.

Considering first some of the salient considerations which are important in the practice of the present invention, the type of matrix or substrate which is employed will initially be discussed. Some properties of the substrate are relatively critical and other are desirable. The substrate should be suiciently weak mechanically to permit penetration by plant shoots in those instances Where penetration of the mulch by the growing plants is to occur, rather than holes being provided in the mulch to accommodate the growing plants. It is essential that the substrate be a biodegradable material which can be decomposed or degraded by naturally occurring soil organisms over the growing season. On the other hand, the substrate should be suiciently strong mechanically to withstand stresses imposed during the coating process and during shipment and handling. It is also necessary that it kbe sufficiently durable to resist erosion and disintegration by moisture and other elements during the major portion of the growing season. In the seed mat embodiments of the invention, it is desirable that the substrate material have relatively good moisture absorption properties.

Since cellulose consuming bacteria are indigenous to most soils, porous cellulosic matrices or substrates can be satisfactorily used in the practice of the invention. Paper and cloth constitute lpreferred materials with the most preferred substrate being newsprint or the cheapest paper which is available. Other types of fibrous substrate materials of animal or vegetable origin can also be employed, and the substrate materials used for the invention are not limited to cellulosic materials. In the case of mulch materials of the seed mat-type, creped kraft paper is preferred in that this -material permits the seeds to be retained in their desired position better than smooth surfaced papers. This paper is also highly adsorbent, thus allowing moisture from the soil to readily contact the seeds through the underneath, i.e., nonbituminous-coated side of the seed mat and aid in seed germination. In contrast, the paper or other substrate for preparation of an agricultural mulch may be, but does not have to be, adsorbent.

The bitumin-containing composition which is applied to the fibrous substrate can be a purely asphaltic material, but preferably is an asphaltic composition containing a major portion of asphalt and up to about 30 percent by Weight of a copolymeric material which is compatible with the asphalt and imparts certain desirable properties to the coating, particularly, suppression of the blocking characteristic, improvement in flexibility, enhanced adherence to the substrate and better moisture-retention properties.

The asphalt employed must meet several functional requirements. It must yield a coating which is flexible enough not to chip or crack when rolled and unrolled or handled. It must not block or adhere in the roll, either in storage or when exposed to direct sunlight in the field. In warehouse storage and in direct exposure to sunlight, summer temperatures as high as F. can be expected. Consequently, the asphalt-containing coating should not block at temperatures as low as 120 F. We have found that an air blown asphalt derived from a cracked petroleum stock and having a softening point of from about 175 F. to 190 F., as determined by ASTM D-36, and a penetration test value at 77 F. of Ifrom 1 to 10 decimillimeters as determined by ASTM D-5, is especially well suited for use in the invention and demonstrates little or no blocking at temperatures as high as F.

In a preferred coating composition which can `be in the invention, asphalt of the preferred type (softening point F. to 190 F. and penetration at 77 F. of between l and 10) is blended with from about 1 percent by 6 weight to about 30 percent by weight of an asphalt ex- The physical and geometric relationship of the bitumintendible copolymer of the ethylene-vinyl acetate type. containing coating to the fibrous substrate is an important Preferably, the composition contains from about 3 to feature inthe present invention, particularly with respect about percent of the ethylenevinyl acetate copolymer. to the embodiment of the invention in which a pure as- Ethylene-vinyl acetate copolymers are sold under the phatic coating is utilized. -In order to permit optimum trade name Elvax by E. I. du Point de Nemours & Combiological decomposition of the fibrous substrate by the pany, Inc., Wilmington, Del., and typical properties of soil organisms, it is believed desirable that the depth of some of the various grades of Elvax which are marketed penetration ofthe coating into the substrate be minimized.

are as follows: The subsequently described examples will illustrate the Copolymer Elvax 150 Elvax 220 Elvax 240 Elvax 250 Comoiiomer Ratio, Wt. percent (ethylene: vinyl acetate). 66:34 to 68:32-- 73:27 to 71:29- 73:27 to 71:29- 73:27 to 71:29

Meir Index (ASTM D-i2as-57T) 22 to 2s 125 to 175 22 to 2s i2 to is.

Refractive Index, N 25.--. 1.485 1.485

Density at 30C., grams/cc Softening Point (Ring and Ball), F Inherent Viscosity, Cp. 30 C.1 Molecular Weight l Determined using a solution of 0.25 weight percent copolymer ln toluene. 2 Crosshead speed of V2 inch per m inute and a sample length of l-inch (ASTM D-882-56T) The ethylene-vinyl acetate copolymers used in the basis for this belief. Some penetration is, of course, reasphalt blends of this invention preferably exhibit melt quired in order to attain the necessary adhesion of the indices ranging from about 3 to about 30, and preferably 25 coating to the substrate. However, beyond the attainment have a vinyl acetate content ranging from about perof a satisfactory degree of adhesion, further penetration cent by weight to about 35 percent by weight. It is further into the substrate is undesirable economically, and also preferred that this copolymer have a tensile strength as appears to deter the decomposing activity of soil orgadetermined by ASTM D-88256T exceeding 1000 p.s.i. nisms in proportion to the depth of penetration. The Elvax 250 described in the Iforegoing table of prop- In the case of the mulch embodiments of the invention,

erties is `an especially suitable material. as opposed to the seed mats, it is further desirable that the In addition to the ethylene-vinyl acetate copolymers, thickness of the coating on the substrate be between 0.5 other asphalt extendible copolymers such as ethylene` and 3.5 miles and preferably not exceed 2.5 mils. Limiethyl acrylate, can also be employed and are used in tation of the coating thickness is obviously desirable from substantially the same proportions as has been described an economic standpoint. Further, however, excessive as a characteristic of the blends of asphalt and ethylenethickness of the coating increases greatly the weight of vinyl acetate copolymer. Ethylene-ethyl acrylate copolythe mulch when it is rolled into large rolls for transport mers are sold under the tradename Zetaiin 70A1 by the or storage, and renders more ditiicult the breaking up or Dow Chemical Company of Midland, Mich. Of the disintegration of the asphaltic coating after the growing ethylene-ethyl acrylate copolymers which can be emseason is tenminated andthe paper substrate has been disployed, the preferred species are characterized by the integrated or decomposed by the soil organisms. The typifollowing typical properties: cal geometric relationship of the coating to the substrate Melt index l 2 5 20 1 is illustrated in FIGURE l of the drawings, wherein reference character 10 designates a newsprint paper substrate isllchwg rzcent llooggg about 4 mils thick which has been coated Iwith an asphalt Elon ation at bgeai' ber''el't'z 670 810 45 coating 12 having a thickness of about 2 mils. The paper Denty 30, C grams/cc 0 4 0 944 10 has'a discolored zone 14 adjacent the coated surface Brime Ont o C '70, which indicates the maximum distance any portion of the Hardnelss Silore 2133-3 3M() coating composition has penetrated into the paper. This distance preferably does not exceed about one ber layer,

ASTM D-123S-57T. 50 or approximately l0 percent of the total thickness of the S' gjgggft 2" per minute crosshead speed substrate (0.4 mil). However, a more meaningful criterion of the penetration is the amount or weight of the The Preference for the USC 0f the copolymer Containcoating composition ywhich pentrates the paper. Preferably ins blends for Coating the fibrous Substrate is based upon this docs not exceed 30 weight percent of thc total amount the improved properties which characterize the coatings of coating composition applied, and most preferably ii derived therefrom. Thus, these coatings appear to adless `than 10 percent of the total weight of the ccmhere more tenaciously to the substrate than pure asphaltic position, coatings, and an improvement in the blocking character- Although it has previously been proposed to provide istics of the coatings is also realized. Moreover, the mulches comprising paper or other types of yfibrous subliexibility of the coating is improved, permitting the mulch strate impregnated or saturated with bituminous compoto be easily rolled without cracking and chipping, or bent sitions, and has further been proposed in broad terms to through relatively small angles without cracking or decoat such substrates with asphalt, no specific consideration struction of the integrity of the coating. This improvehas been given to the criticality of the relationship bement is particularly evidenced when the amount of cotween the position and thickness of `the coating with refpolymer in the blend exceeds about 7 weight percent. 65 erence to the substrate. Such coatings and impregna- The described copolymer materials form a homogenous tions have been accomplished by a number of techniques, blend or sol with the asphalt, and do not present any including spraying, dipping, and applications with doctor problems in handling. The lblends are particularly well blades and brushes. Necessarily, many of these techniques adapted for use in the curtain coating or gravitating film result in coatings which are thicker than desirable, or method of manufacturing mulches hereinafter described. which completely saturate or deeply penetrate the sub- Further, from limited available evidence, the inclusion strate, or which are not uniform over the entire areal of the copolymer appears to slightly reduce the depth to surface of the substrate, and therefore do not transmit which significant quantities of the coating composition evenly the Warmth absorbed from the sun to the soil bepenetrate into the substrate. The importance of this propneath the mulch, and do not retain in a uniform manner4 erty is deserving of some discussion. the moisture in the soil beneath the mulch.

One of the novel and important aspects of the present invention is the highly effective technique which is proposed for applying bitumin-containing compositions to the fibrous substrate in manufacturing the mulches of the invention. The proposed procedure entails developing a thin, gravitating film or curtain of the molten coating composition, and passing the substrate at a uniform rate of speed through the curtain at a point sufficiently removed from, the source or origin of the curtain to provide a uniform coating of the desired thickness on the substrate. An apparatus which has been effectively employed for this purpose is depicted schematically in FIGURE 2 of the drawings. Such apparatus is commercially available and is known to industry as the Steinemann curtain coater. Although curtain coating devices have heretofore been utilized for applying various types of coatings to paper stocks or substrates, we believe we are the rst to propose the application of predominantly asphaltic compositions to a fibrous substrate with the curtain coating technique for the purpose of providing an improved agricultural mulch.

Referring lto FIGURE 2, the curtain coating machine includes a coating head 16, from which originates the gravitating curtain of the coating composition, and a trough 18 which receives the composition and permits it to be recirculated to the head via a conduit 20 by means of a pump 22. The gravitating curtain of the bitumincontaining coating is represented by dashed lines and is designated by reference character 24. Spaced above the trough 12 and occupying substantially the same horizontal plane are a pair of conveyors designated by reference characters 26 and 28. The conveyor 26 may be termed the input or fed conveyor, and one simple form may comprise a wide belt which passes around a roller 30 positioned adjacent the gravitating curtain 24 and slightly to one side thereof. The conveyor 28 may be designated the discharge conveyor and also compirses a wide belt which passes around a roller 32 positioned adjacent the gravitating curtain 24 and on the opposite side thereof from the roller 30. The conveyors 26 and 28 are aligned so that the fibrous substrate may be moved into the curtain 24 on the fed conveyor 26 and picked up and discharged on the conveyor 28. A grill 34 is supported in the trough 18 and supports the substrate as it moves through the curtain 24. Where extremely long, continuous sheets of the -fibrous substrate are to be coated with the bitumin-containing composition, the conveyors 26 and 28 will not be used to move the substrate through the gravitating curtain. Instead, a feed roll and take up roll (not shown) may be disposed on opposite sides of the curtain at a substantial distance therefrom, and may be used to pass the substrate material through the curtain.

In applying the asphaltic coatings of the present invention by the preferred curtain coating technique, the composition is heated to a temperature Within the range of from about 225 F. to about 325 F., and preferably from about 280 F. to 305 F. These temperature ranges will generally apply equally well to the pure asphaltic coating composition, or to blends of the asphalt with asphalt extendible copolymers because of the relatively small proportion of copolymer which is normally present.

In order to achieve the thin, uniform coating with only slight penetration which is highly preferred in the mulches of the present invention, several factors must be considered in the curtain coating procedure. These include the speed at which the substrate is passed through the curtain, the Viscosity and temperature of the molten composition and the circulation rate of the coating composition through the closed system. The height of the coating head above the plane occupied by the substrate as it is passed through the curtain and the width of the slot in the coating head are of minor importance.

The substrate may be moved through the curtain at speeds yranging from about 400 feet per minute up t0 2000 feet per minute for the purpose of applying coatings ranging from about 0.5 mil up to about 3.5 mils when employing normal composition recirculation rates in the curtain coating device of from about 5 lbs. per minute to about 30 lbs. per minute. The coating head will normally be spaced a distance of from about five to ten inches above the substrate and preferably six to seven inches. The slot in the coating head from which the curtain originates is preferably about 0.125 inch in width. Using the described curtain coating technique, we have found that a penetration of the bitumin-containing composition into the substrate does not exceed about 0.5 mil when the curtain coating is carried out under the prescribed conditions.

Before referring to specific examples of the practice of the invention for purposes of further clarifying its salient features and important advantages, one further aspect of the invention should be considered. This is the embodiment of the invention which comprises the preparation of improved seed mats employing the 'basic principles of the invention with slight modifications in hereinbefore prescribed procedures, primarily with respect to the type of substrate material which is utilized, and the thickness of the coating which is applied. This aspect of the invention comprises the preparation of a seed mat which contains seeds embedded in or positioned on the surface of the fibrous matrix or substrate, and retained in position `by the coating which is applied to the substrate. In the preparation of such seed mats, a creped or wrinkled kraft paper is preferably utilized since the seeds will remain in undulations or depressions on the creped paper and will not readily shift on the surface of the paper dur-ing the coating operation. This type of seed mat is illustrated in cross-section in FIGURE 3 of the drawings. As an alternative embodiment, the seeds may be embedded in a thin web of fibrous material which is then coated with the bitumin-containing composition. The embedding of the seeds prevents their shifting from the desired location in the substrate, and allows the coating to be applied more smoothly and uniformly. In either arrangement, it is desirable that the seeds 36 not be completely surrounded or enveloped by the coating material so that interference with germination of the seeds and their projection of root systems through the substrate result. We have found that, not only should the bottom of the seed which is in contact with the substrate not be coated with the asphaltic material, but it is also preferable to apply the coating in a suliiciently thin layer that the top of the seed 36 is luncoated and exposed as shown in FIGURE 3. For a reason which is not clear, better exposure of the upper surface of the seeds is obtained when blends containing about 10 weight percent of the copolymer are used, rather than pure asphalt, or blends containing a lesser amount of copolymer.

In the manufacture of seed mats of the type described, several additional properties of the coating are important. With respect to any seeds which are covered with the asphaltic material, the film strength of the coating .must be sufficiently low to permit emergence of shoots or sprouts from the germinat-ing seeds. A mean coating thickness of from 3 to 6 mils will generally be utilized, with the thickness of any coating which directly covers any seeds not exceeding 0.5 mil. Either the pure asphalt or asphalt-copolymer coating compositions can be used, although better growth rates have been observed in the case of Bermuda grass seed mats coated with blends of asphalt and ethylene-vinyl acetate copolymer, and particularly, blends containing about l0 weight percent of this copolymer. When this -blend is applied by the curtain coating technique, about 75 per cent of the seeds can be left exposed at the upper surface.

Many types of seeds may be utilized in the seed mats of the invention, including grass seeds and var-ions types of row crops and small grain crops. The seed mats afford a particularly desirable way of planting seeds of this type,

since the seeds are relatively small and a good number of them may be lost due to wind conditions when broadcast or not covered suflciently with the soil.

It should be further noted that it is within the scope of the present invention to impregnate the matrix or substrate of the seed mat with certain beneficial chemicals, such as fertilizers, insecticides and fungicides, provided primarily that the biodegradable property of the substrate is not completely or substantially destroyed by the use of such additives for impregnating the substrate.

As a final consideration which is applicable to both the mulch and seed-mat embodiments of the invention, it is preferable to apply by sprinkling or other suitable technique, a small amount of abrasion resistant material, such as zinc or magnesium stearates, to the coated substrate prior to forming it into rolls for shipment or storage. This aids in preventing blocking of the coating and reducing loss of the coating through abrasion by contact with the uncoated surface of the substrate in the rolls.

In using both the seed mats and mulches prepared in accordance with the present invention, the fibrous substrates with their associated bitumen-containing composition coatings are unrolled or otherwise suitably laid out in strip form on the soil surface with the coated side up. Positioning of the 'mulch or seed mats may be accomplished either manually or mechanically, and the strips are anchored by lumps of soils, pegs, or rid-ges of earth placed in position by methods Well understood in the art.

The following examples will serve to further explain the invention and demonstrate the advantages which are attributable thereto.

EXAM-PLE 1 Various bitumen-containing compositions were applied to sheets of 201/2 pound mill glazed sulte paper with a heated drawknife while the paper was rested on a warm hotplate. The -thickness of the applied coatings was calculated from the weight of the applied coating composition.

In testing the flexibility of the applied coatings, the coated compositions were bent on a radius of about M6 inch at room temperature and the extent of fracturing or cracking observed.

Blocking tests of the coating compositions were run by covering the coated sides of the mulch papers with a piece of clean paper. A pressure of about 0.5 p.s.i.g. was applied to the clean paper and retained -for about seventeen hours at the temperatures selected for the blocking tests. The paper coverings were then pulled away from the mulch papers and the percentage of the loaded area to which bitumen adhered was recorded at the percent of blocking which occurred.

In some of the blocking tests, the coated Itnulch paper was dusted with talc of a known amount prior to covering with the clean blocking paper.

The results of these tests are set forth in Table I and the properties of the asphalts used in the `tests are set forth in Table II.

TAB LE I Composition o! Coating, Weight Percent:

Elvax 250 ethylenevinyl acetate copolymer Propane Reduced Asphalt Cracked Asphalt No. 1 Blown Roofing Asphalt Cracked Asphalt No. 2-.

Properties of coating on Pound Paper:

Thickness, mils 1. 05 1. 67 1. 86 1. 47 0. 91 0. 73 Flexibility Good Good Good Good Good N0 talc Percent Blocking at 75 F. None None None Percent Blocking at 100 F 100 20-25 10-20 None Percent Blocking at 120 F 100 100 50 30 Percent Blocking at 140 F.-- 100 100 100 100 100 100 Tale Adhering at 75 F., Grams per square foot 346 259 346 072 530 187 Percent Blocking at 75 F None None None None Percent Blocking at 100 F None None None None Percent Blocking at 120 F Trace 50 5-10 None Percent Blocking at 140 F 510 Trace 100 75 5-10 Stain Tale Adhering at 140 F., Grams per square foot 259 274 259 288 288 TABLE II Asphalt Propane Reduced Cracked No. 1 Blown Roofing Cracked No. 2

Sottening Point, F 175 182 208 151 Penetration at 77 F. (100 grams and 5 seconds), in

decimillimeters 4 4 32 7 Specific Gravity 1. 098 1. 135 1. 076 1.141 Ductility at 77 F. (5 cm.lmin.), in cm 150+ 150+ 3 150+ Viscosity at 300 F., in centistokes 1, 465 175 In the case of the mulch strips, the crops can usually be planted by punching holes through the mulch at the center thereof and planting the seeds through such holes. In the case of a few crops, such as pineapples or sugar cane, which develop strong spikes in the course of their growth, provision of apertures or holes in the mulch is not required since the shoots of spikes of the growing plant will penetrate through the mulch. It should further be pointed out :that although the highly preferred method of applying the asphaltic coating to the brous substrate is the curtain coating technique hereinbefore described, other, more conventional procedures may be utilized, provided that in the case of the purely asphaltic coatings, a thin uniform layer not exceeding 3.5 mils in thickness (about 6 mils in thickness in the case of the seed mats) can -be applied to the substrate without the occurrence of penetration of the coating into the substrate to a depth exceeding about 0.5 mil.

EXAMPLE 2 Coatings of the various bitumin-compositions described in Example l were applied in fairly thin (about l mil) films to mucilage-ooated paper, and the paper then removed by soaking in water. None of the separated, unsupported lms of asphaltic compositions could be 'lifted from the water without dsintegrating, thus 1 1 showing a complete lack of cohesion and tensile strength, and indicating that the coating of the mulch strips can be easily disintegrated and plowed under the soil after soil organisms have destroyed the paper substrate.

rated roofing paper were removed from their test environments and allowed to dry. All of the samples were then examined microscopically and visually. The results of these examinations are summarized in Table IIL TABLE III Soil 4 Mo. Incuba- Minimal Agar 3% Sabouraud Agar 4 Sabouraud Agar 3% Mo tion Mo. Incubation Mo. Incubation Incubation Newsprint (not coated) Intact but strength Intact but stregnth Intaet but strength Intact but strength loss. loss. loss. loss. Roofing Paper No damage No damage No damage No damage. Asphalt Coated Newsprlnt Intact but strength Intact but strength Intact but strength Intact but strength loss. los. loss. los. Asphalt Impregnated Newsprint .do o o. Krait Toweling (not coated) Destroyed dO do-.. D0. Newsprint Coated with Asphalt and 5% Elvax 250 1 Inltact but strength do .do Do.

oss. Newsprint Coated with Asphalt and 7 Elvax 250 do do .do Do. Kraft Toweling Seed Mat Coated with l)Asphalt and 5% Paper destroyed all Paper destroyed Paper destroyed al1 D0.

Elvax 250. strength 10st. asphalt mtact. strength lost. Kraft Toweling Seed Mat Coated with Asphlat and 10% .do Paper destroyed all Dc.

Elvax 250. strength lost.

l All percents are weight percent.

EXAM-PLE 3 A number of -tests were run upon mulches and seed mats prepared in accordance with the present invention in which these articles were subjected to artificially induced degradation for a period of two weeks. 'In the tests, the samples were subjected to intimate cont-act with an inoculum of relatively pure strains of cellulose decomposing fungi. In preparing the inoculum, cultures of Poria Nigrescems-'485'6, Chaetomium Funicolum-R49A, R-6 (Fungi Imperfecti), Phialophora Richandsiae-R-7, and R-Zl (Fungi Imperfecti) were grown on Sabourauds agar and the spores of these fungi were then harvested. The Sabourauds agar Iis a semisolid medium specilically designed for fungal growth and consists of glycose, peptone, water and agar. A mixed spore suspension of these six cultures was then made in water and used to spray the mulch samples.

In some of the tests, mulch and seed mat sample discs about 2 inches in diameter were placed on top of Sabourauds agar in petri dishes with the coated side up, and were then sprayed with the six-culture inoculum. The plates were then incubated in a water saturated atmosphere at C. In other tests, the discs were supported on a minimal agar medium which consisted of z MgSO4-7H2O, g. 0.2 (INH4)2SO4, g. 0.2 Na2HPO4, g. KH2PO4, g. CaCl2, g. 0.10 Yeast extract, g 0.03 Glucose, g. 0.03 pH 5.8 Agar, g. '15.0 H2O, liter 1 The minimal agar medium was used in some of the tests because in this medium, the organic content is so 10W as to be only stimulatory and not growth supporting. Thus, any significant fungal growth that took place did so as a result of using the mulch samples as food for the fungi. Incubation and inoculation of mulch samples on this medium -was the same as with the Sabourauds agar medium.

In a lthird series of artificially induced degradation tests, soil containing decaying organic debris was mixed with soil taken from a cattle feed lot and placed in small glass containers. Discs 4of the mulch were placed on the surface of the soil, then inoculated with spore suspension and Iincubated in the same manner -as were in the agar plates.

After 31/2 to 4 months in the test environments, the mulch and seed mat samples, along with comparative uncoated paper samples and one sample of asphalt satu- In referring to Ta-ble I'II, it will be noted that significant degradation was observed in the case of all of the samples except for the rooting paper sample which consisted of paper impregnated to saturation with asphalt.

In addition to the microscopic `and visual examinations of the samples, tensile strength tests were made on the uncoated paper, mulch and seed mat samples that were removed intact from the soil and minimal agar environments. All of the samples thus tested showed significant strength losses. The asphalt impregnated newsprint, however, underwent ya smaller decrease in strength than asphalt coated newsprint, thus indicating that penetration of the asphalt into the substrate to a relatively great extent should preferably be avoided. The newsprint coated solely with asphalt, as well as the newsprint muches coated with blends of asphalt and the Elvax copolymer all compared favorably in degradation and loss of tensile strength to the uncoated newsprint, indicating that with the relatively thin and superficial coatings of the asphaltic compositions used in the present invention, the normal rate of deterioration of paper in contact with soil organisms is not detrimentally affected by the presence of the coating compositions thereon. In all of the samples tested, the asphalt employed was the air blown cracked asphalt hereinbefore described.

EXAMPLE 4 In order to better evaluate the physical properties of the asphalt containing coating applied to cellulosic substrates using the curtain coating technique hereinbefore described, a number of tests were run in which various mulches and seed mats were prepared by the curtain coating procedure, and the coated samples then subjected to examination and testing which included measurement of the thickness of the applied coating, the contact and penetration of the coating on and into the substrate, the contact and thickness of the coating over the seeds utilized in the seed mat, the frequency of cracks in the coating, and the surface texture. The coated mulch and seed mat samples Were compared with untreated substrates of the type used in preparing the mulches and seed mats. The asphalt used in all of the coating compositions was the air blown cracked asphalt hereinbefore described.

The samples were examined in two ways. In the rst of these, the surface of each of the samples was examined using a low power, 30 magnication stereoscopic microscope. In the second type of examination, cross sections of the samples were examined using a metallographic microscope at medium power from 200 to 340 magniiication with reflected, polarized lighting. The cross sections were prepared by laying the samples with the coated side down on a iirm, Masonite surface which was heated to about C. This slightly elevated temperature reduced the brittleness of the coating to permit the samples to be more easily sectioned. Cutting of the samples was done with double-edged razor blades, and a new edge was used for each section.

The results obtained in these tests are set forth in Table 1V along with a description ofthe type of substrate in the case of those mats coated with a 4 mil coating of the blend containing 10 weight percent of the Elvax 250. In these mats about 75 percent of the seeds were exposed at their upper surface. 'I'his indicated that exposure of the and coating composition used 1n each sample. 5 upper surface of the seeds 1s desirable, and that use of TABLE IV [Thickness Measurements in Mils] Asphalt Penetration Frequency of Frequency of Surface Sample Paper 1 Asphalt l Total l on Seedsfz oftAslphalt Exposed Seeds Surface Cracks Texture in o aper Asphalt Impregnated Newsprint 3.8 Complete None found Dull, variable, Asphalt+10% Elvax250 onNewsprint- 3. 5 1.2 4.7 0.46 Low Some gloss,

but variable. Untreated N ewspzint (-198-3) 4. 2 Smocther than 1 roe. Asphalt+5% Elvax 4 on Newsprint..- 3. B 2. 5 6.3 0.4 avg High Smooth. Asphalt+10% Elvax on Newsprlnt,.-- 3.4 2.0 5.4 0.4-0.7 None found Striated. Asphalt-|-10% Elvax on Nibroc Kraft 4. 4 4. 0 8. 5 3.0-0 3-.-- 0 to 0.4 75% do Rough and Paper Toweling. irregular. .Asphalt+5% Elvax on Nibroc Krait 4. 5 3. 6 8.0 1.2 to 0.-. 0 to 0.4 Low Highest., much Smooth.

Paper Towelng. chipping. Untreated Nibroc Krait Paper Towel- 4. 6 Rough; ridges ing. coarser fibers than newsprint. Aspha1t-l5% Elvax on Nibroc Kraft 5.6 6.1 12. 0 3.0 0 to 0.4 Very low; none High; some Smooth.

Paper Toweling. und. chipping. Aspha1t+5% Elvax on Nibroc Kraft 4.9 3.5 8.4 2.1 to 0... Low, poor Low .do Do.

Paper Toweling. contact. smalti-10% Elvax on Nibroc Krait 4. 2 5. 7 9. 9 3.0 to 0.-. Some stain 10-20% Very low Slightly rough.

Paper Toweling. on back. Aspha1t+10% Elvax on Nibroc Kraft 4. 9 2. 8 7. 7 1.0 to 0.-. 0 to 0.4 50% nd0 Do.

Paper Toweling.

l Average of 100 measurements. Asphalt on Seeds. Paper Co.

2 Average of 10 measurements.

From the data appearing in Table IV, it will be apparent that the newsprint substrate absorbed the coating material slightly more than did the Nibroc kraft paper toweling. It further appears that the substrate is compressed slightly by the coating process. It will be noted that the penetration of the asphalt into the substrate when employing the curtain coating procedure rarely exceeds about 10 percent of substrate thickness, and that the thickness of the applied coating can be relatively easily maintained under about 3 mils in the case of the mulch samples and about 6 mils in the case of the seed mat samples. Thus, the curtain coating procedure oiers economic advantages in maintaining the coating relatively thin, and penetration at a relatively low value, and also perimts the desired rate of biodegradation to be achieved by avoiding saturation land impregnation of the substr-ate with the applied coating material. It is further to be noted that the inclusion of the copolymer in the coating blend does not appear to measurably alect the depth of penetration of the blend into the substrate, with the figure of about l percent of the substrate thickness being penetrated applying generally.

Though a relatively low copolymer content (about percent) is less effective in preventing chipping and cracking, it makes for a smoother coating than the blends containing percent of the copolymer. On the other hand, it will be noted that in the case of the seed mats, the incidence of exposed or uncovered grass seeds which occurred when the coating composition containing l0 weight per cent of the Elvax 250 copolymer was employed was considerably higher than the incidence yfo exposed grass seeds when the blend containing 5 percent of this copolymer was employed. Thus, in the case of seed mats prepared using a coating composition containing l0 weight percent of the Elvax 250, as high as 75 percent of the seeds remained exposed -at their upper surface.

EXAMPLE 5 Bermuda grass seed mats prepared as described in Example 4 were placed in a greenhouse in an environment conducive to germination. Germination of the seeds was perceived to occur within ten days after placing the seed mats in contact with the soil. The best growth occurred 3 Only measurements of coated seeds were included in averages in column 4 Elvax copolymer used in all blends was Elvax 250.

Nibroc is a creped kraft paper toweling produced by the N. I. Brown blends `containing 10 weight percent of the copolymer are to be preferred to the blends containing only 5 weight percent thereof for purposes of manufacturing the seed mats of the invention.

EXAMPLE 6` Field tests were conducted in which one of the mulches prepared by the curtain coating procedure and described in Example 4 was used for mulching a crop of muskmelons. This mulch comprised a newsprint having a thickness of about 3.5 mils coated with about 1.2 mils of air blown cracked asphalt containing 10 weight percent Elvax 250. The depth of penetration of the coating into the substrate was about 0.46 mil. For purposes of comparison, sheeets of 4black pigmented polyethylene mulch paper having a thickness of 1.25 mils were used concurrently in the same field for mulching certain rows of the muskmelon crop. Tensile strength tests of the mulches prepared in accordance with the present invention were made prior to mulching the muskmelon crop, as well as after the mulch had been in use for a period of 103 days.

After the 103 day weathering period and following completion Of the growing season of the muskmelons, it was observed that the mulches had deteriorated to an extent such that only selected areas could be lifted from the ground to provide strips of suflicient size to be subjected to tensile strength tests. Furthermore, only a few of the strips which were lifted from the ground were coherent enough to withstand handling during the tensile strength test. The polyethylene, on the other hand, was substantially intact and had undergone relatively little weakening. The plastic characteristic 0f the polyethylene was retained so that even after rototilling, long strips of the polyethylene remained in the soil and on the surface thereof. On the other hand, rototilling of the mulch of the present invention resulted in the complete disintegration of the mulch and comminution thereof into very small pieces.

Table V sets forth data from the tensile strength tests of the mulch of the present invention, showing the results of such tests obtained both 'before and after the weathering of the mulch during the l03-day maturing period of the muskmelon crop. The tensile strength tests were performed on an Instron tensile testing machine.

TABLE V.-EFFECT OF WEATHERING ON STRENGTH OF MULCH [3.5 mils newsprint coated with 1.2 mils of asphalt blend containing wt. percent Elvax 250] Average tensile elongation, inches (E):

Before mulching (a) 0.54 After mulching for 103 days (b) 0.70 Average tensile strength, lb. (T):

Before mulching (a) 10.4 After mulching for 103 days (b) 4.7 Toughness (ET/2):

Before mulching (a) 2.7 After mulching for 103 days (b) 1.63 Percent deterioration in toughness 100-100 39.5

Eb Tb L EaTa Average tear strength, lb.:

vBefore mulching 2.0 After mulching for 103 days 1.4 Percent deterioration in tear strength 30 Although certain preferred embodiments of the invention have been heretofore described by way of example, it will be understood that some modification and variation may be made in the proportions indicated, and in the materials to which reference has been specifically made, without departure from the basic principles which underlie the invention. lnsofar as such modifications continue to rely upon the fundamental principles which are hereinbefore described, they are deemed to be circumscribed fby the spirit and scope of the invention except as the same may be necessarily limited Iby the appended claims or reasonable equivalents thereof.

What is claimed is: 1. An agricultural mulch comprising: an elongated flat strip of paper; a coating adhered to one surface to said flat strip of paper and having a thickness not exceeding about 3.5 mils, said coating comprising:

from about 70 percent by weight to about 99 percent by weight of a cracked asphalt having a softening point of from about 175 F. to about 190 F. and having a penetration at 77 F. of from 1 to l0 decimillimeters, and

from about 1 percent by weight to about 30 percent by Weight of a copolymer selected from the group consisting of ethylene-vinyl acetate and ethyleneethyl acrylate copolymers.

2. An agricultural mulch comprising:

(a) an elongated at strip of fibrous, biodegradable,

air permeable cellulosic material, and

(b) a coating adhered to one surface of said flat strip of iibrous, biodegradable, air permeable cellulosic material, said coating having a thickness not exceeding about 3.5 mils, said coating comprising:

( 1) from about 70 percent by weight to about 99 percent by weight of an asphalt which demonstrates little or .no blocking at temperatures as high as F., and

(2) from about 1 percent by Weight to about 30 percent by weight of a copolymer selected from the group consisting of ethylene-vinyl acetate and ethylene-ethyl acrylate copolymers.

3. An agricultural mulch as claimed in claim 2 wherein the asphalt is a blown asphalt derived from a cracked petroleum stock and having a softening point of from about F. to about 190 F. and a penetration at 77 F. of from l to 10 decimillimeters.

4. An agricultural mulch comprising:

(a) an elongated at strip of fibrous, biodegradable,

air permeable cellulosic material, and

(b) a coating adhered to one surface of said cellulosic material, said coating penetrating said cellulosic material not more than about 0.5 mil and comprising:

(l) from about 70 percent by weight to about 99 percent by weight of a blown asphalt derived from a cracked petroleum stock and having a softening point of from about 170 F. to about F. vand a penetration at 77 F. of from 1 to 10 decimillimeters, and

(2) from about 1 percent by weight to about 30 percent by weight of a copolymer selected from the group consisting of ethylene-vinyl acetate and ethylene-ethyl acrylate copolymers.

References Cited UNITED STATES PATENTS 1,534,371 4/ 1925 Finley 47-9 1,534,372 4/ 1925 Finley 47-9 1,846,186 2/ 1932 Cline et al. 1,956,045 4/ 1934 Richter. 2,314,181 3/ 1943 Winterkorn 26o-28.5 2,418,135 4/ 1947 Moore et al. 260-28.5 2,721,146 10/1955 Hardman 117-158 X 2,972,588 2/1961 Cohen 117-158 X 3,085,731 4/ 1963 Wilkins. 3,249,567 5 1966 Vigneault. 3,274,138 9/1966 VSalvesen 260-28.5

FOREIGN PATENTS 522,694 3/ 1956 Canada.

WILLIAM D. MARTIN, Primary Examiner.

M. LUSIGNAN, Assistant Examiner.

U.S. Cl. X.R. 

